Refrigerator/freezer insulation blanket and packaging solution

ABSTRACT

A combined shipping and insulation cover for an electrical appliance comprises a hood of insulating material and layer of polymer film. The cover includes a tear off panel connected to the hood by a perforated score line that allows access to the underlying electrical appliance.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to the product packaging field and, more particularly, to a combined shipping and insulation cover for a refrigerator, freezer or refrigerator-freezer.

BACKGROUND OF THE INVENTION

Electrical appliances, such as refrigerators, freezers and refrigerator-freezers, undergo significant handling and shipping prior to delivery and use. Significant time, effort and expense are invested in shipping containers for such electrical appliances. For example, the front, top and side faces of a chest freezer are covered with a protective material. Corner boards of foam or cardboard may be provided to protect the corners. Finally, an outer cardboard box encloses the chest freezer and completes the shipping container.

It should be appreciated that the outer cardboard box is typically made from corrugated cardboard material. Such material is relatively heavy thereby adding to shipping weight and shipping costs. The outer cardboard box is also a waste material that must be disposed of after delivery of the chest freezer. The material is relatively heavy and cumbersome to haul away and takes up substantial space in any landfill.

The present invention relates to a new and improved cover for electrical appliances such as refrigerators, freezers and refrigerator-freezers as well as to a new and improved method for reducing shipping costs as well as shipping waste associated with shipping such an electrical appliance.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a combined shipping and insulation cover is provided for an electrical appliance. The cover comprises a hood of insulating material. The hood of insulating material is provided in a shipping position covering the electrical appliance. The cover further includes a layer of polymer film extending around the hood of insulating material and holding the hood of insulating material on the electrical appliance in the shipping position. Further, the cover is characterized by having a tear off panel connected to the hood by a perforated score line.

In accordance with yet another aspect of the present invention, a combined shipping and insulation cover for an electrical appliance such as a refrigerator, freezer or refrigerator-freezer, comprises a hood of insulating material provided in a shipping position covering the electrical appliance. The cover further includes a layer of polymer film extending around the hood of insulating material and holding the hood of insulating material on the electrical appliance in the shipping position. The cover is further characterized by including a main body and an access panel. The access panel covers a door of the electrical appliance. The access panel is connected to the main body by a hinge line so that the access panel allows the door of the electrical appliance to be opened and closed with the cover in place on the electrical appliance after the layer of polymer film is removed and the electrical appliance is placed in service. As the cover has insulative properties it can reduce energy consumption and energy costs relating to operation of the electrical appliance. The cover is particularly useful for appliances exposed to temperature extremes such as found in unconditioned air spaces including garages and the like.

In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is a top plan view of a blanket of insulating material that may be used to construct the cover of the present invention;

FIG. 2 a illustrates the cover of the present invention in a shipping position with the main body of the cover covering the front, rear and side faces and the flap covering the top face or door of a chest freezer;

FIG. 2 b illustrates the cover and chest freezer of FIG. 2 a with the door of the chest freezer open;

FIG. 2 c is a detailed schematical view illustrating an optional skirt that may be provided on the hood in order to overlap the seal of the chest freezer when the door of the freezer is closed;

FIG. 3 is a perspective view of the cover of insulating material incorporating pockets holding removable corner guards or corner protectors;

FIG. 4 a is a detailed plan view illustrating the tear off panel of the cover and the perforated score lines that connects the tear off panel to the cover;

FIG. 4 b shows the tear off panel of FIG. 4 a removed to expose the controls of the chest freezer; and

FIG. 4 c is a side elevational view illustrating how a tear off panel is removed from the cover to expose vents for the refrigeration system of the chest freezer;

FIG. 5 illustrates a cover including two flaps for covering both doors of a side-by-side refrigerator so as to allow opening and closing of the doors with the cover in position on the refrigerator;

FIG. 6 illustrates a cover including two access panels for covering the two doors of a top mount freezer and bottom mount refrigerator appliance;

FIG. 7 illustrates a cover including two access panels for covering a top mount refrigerator door and bottom mount freezer drawer appliance;

FIG. 8 illustrates a cover including three access panels for covering a two-door top mount refrigerator and a bottom mount freezer drawer appliance; and

FIG. 9 illustrates a cover for an upright freezer.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Reference is now made to FIGS. 1, 2 a and 2 b illustrating the combined shipping and insulation cover 10 of the present invention used to cover an electrical appliance illustrated in FIGS. 2 a and 2 b as a chest freezer F. As should be appreciated, the cover 10 comprises a hood 12 of insulating material and a layer of polymer film 14.

As best illustrated in FIG. 1, the hood 12 includes a first portion or flap 16 and a second portion or main body 18. The lines 20 define cut lines while the line 22 defines a fold line or hinge line extending between the cut lines whereby the flap 16 is hingedly connected to the main body 18.

As best illustrated in FIG. 2 a, the hood 12 is provided on the chest freezer F in a shipping position wherein the main body 18 covers the front face, the rear face and two opposing sidewalls or faces of the chest freezer F while the flap 16 covers the top face or door D of the chest freezer F. The layer of polymer film 14 extends around the hood 12 of insulating material and holds the hood of insulating material on the chest freezer F in the shipping position. Together, the hood 12 and polymer film 14 provide a lightweight and durable protective shell for the chest freezer F.

The hood 12 is made from an insulating material selected from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthatlate, polybutylene terephthatlate and combinations thereof. The insulating material may also include reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations or mixtures thereof.

In one particularly useful embodiment of the hood 12, the insulating material includes a densified outer skin as described and illustrated in issued U.S. Pat. Nos. 6,539,955 and 6,669,265, both to Tilton et al and assigned to the assignee of the present invention. The full disclosure of these two patents is incorporated herein by reference. It should be appreciated that the densified skin provides a tough outer coating. It should further be appreciated that the hood 12 including the densified skin is a non-laminate and, thus, it is not subject to potential delamination.

Advantageously, the tough densified outer skin is both flexible and tear resistant and, accordingly, will resist damage during handling of the chest freezer F including engagement with the paddles or forks of a lift truck during shipping. Such paddles commonly tear and damage corrugated cardboard cartons often leading to discounts in pricing for the electrical appliances contained in those cartons. In many instances, the hood 12 will resist that damage thereby eliminating the need for “shipping damage discounts”. This saves the manufacturer significant money thereby increasing profitability. Similarly, while corrugated cardboard cartons or boxes may lose integrity and deteriorate when wet, the outer polymer film/stretch wrap layer 14 of the cover 10 is water impervious. Thus, the hood 12 maintains full integrity so undesirable potential shipping discounts are once again avoided. The hood 12 and layer of polymer film 14 of the cover 10 function together to protect the chest freezer F during shipping effectively eliminating the need for the outer corrugated carton. This reduces weight thereby saving shipping costs. Further, it eliminates this corrugated cardboard material from the waste product stream. Significantly, the cover 10 is also green friendly as it is free of wood products. In contrast, trees are used to produce the corrugated cardboard outer packaging of the prior art.

As illustrated in FIG. 3, the cover 10 and, more particularly, the hood 12 may include pockets 24 on the main body 18 positioned so as to overly the corners of the chest freezer F when the hood is in the shipping position. A removable corner guard or corner protector 26 is provided in each pocket 24. More specifically, each corner protector 26 is made from a material selected from a group consisting of cardboard, fiberboard, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof. This includes pultruded products and resin enhanced VersaMat materials available from Owens Corning. In the illustrated embodiment the corner protectors 26 are inserted into the pockets 24 which are open at the top. Thus, the protectors 26 may be removed if desired. In an alternative embodiment (not shown) the corner protectors 26 may, be permanently affixed to the hood 12 by adhesive or other means. In such an embodiment, the pockets 24 may be eliminated.

Prior to placing the chest freezer F into service, the layer of polymer film 14 is removed. For some applications, the corner protectors 26 may also be removed. These are the only waste materials from shipping. Thus, it should be appreciated that the hood 12 may be maintained on the operating electrical appliance or chest freezer F. More specifically, first fasteners 28 may be provided for securing the main body 18 of the hood to the front face, rear face and side walls or side faces of the chest freezer F (see FIGS. 1, 2 a, 2 b and 3). Such a fastener 28 may comprise cooperating hook and loop fasteners wherein one component of the fastener is adhered to the wall of the chest freezer F while the other component of the fastener is adhered, sewn or otherwise attached to the hood 12. Similarly, second fasteners 30 are provided for securing the access panel or flap 16 to the door D of the chest freezer F. Thus, as illustrated in FIG. 2 b, when the door D is opened, the access panel 16 pivots with the door D along the hinge line 22 thereby allowing unimpeded access to the interior of the chest freezer F.

As further illustrated in FIGS. 4 a-4 c, the hood 12 may also include a tear off panel 32 that is connected to the hood 12 by a perforated score line 34. Prior to placing the chest freezer F into service, the tear off panel 32 may be removed by tearing along the perforated score line 34. Thus, for example, it is possible to remove a tear off panel 32 to expose freezer controls C (see FIG. 4 b) or vents V (see FIG. 4 c) in order to allow the refrigeration system of the chest freezer F to breathe. Still further, as illustrated in FIG. 2 c, the flap 16 may include a depending skirt 17 that hangs downwardly when the door D of the chest freezer F is closed. In this position, the skirt 17 overlies or covers the door seal S so as to insulate that seal and increase the operating efficiency of the freezer F.

As should be appreciated from the above description, the cover 10 of the present invention provides a number of benefits and advantages. The cover 10 better resists many shipping abuses than a state-of-the-art corrugated cardboard carton. Further, the cover is green friendly. In addition, the hood 12 of the cover 10 may be utilized to provide additional thermal and acoustical insulation for the electrical appliance/chest freezer F after it is placed in operation. While perhaps not appropriate for use on a chest freezer F provided in a finished room of the home, it should be appreciated that many chest freezers F are maintained in unconditioned air spaces such as garages. Such chest freezers F are exposed to temperature extremes in both the summer and winter that may lead to inefficient operation of the chest freezer that increases operating costs. Advantageously, since the hood 12 is made from insulating material it can protect the chest freezer F from these temperature extremes and allow it to be operated more efficiently and at a reduced cost. Further, as described above and illustrated in FIGS. 2 a and 2 b, the hood may be maintained in place to provide this benefit and at the same time not interfere with access to the consumer goods held in the freezer F as the access panel 16 hinges with the door D.

An alternative embodiment of the present invention is illustrated in FIG. 5. This cover 50 includes a hood 52 including a main body 54, a first access panel 56 and a second access panel 58. The main body 54 covers the two sidewalls and the top wall of the side-by-side refrigerator R. The first access panel 56 is connected to the main body 54 by the hinge line 60 while the second access panel 58 is connected to the main body 54 by the hinge line 62. As should be appreciated, the first access panel 56 is secured to the first door D₁ of the refrigerator R while the second access panel 58 is secured to the second door D₂. When the door D₁ is opened or closed, the first access panel 56 hinges about the hinge line 60 and freely moves with that door. Similarly, when the second door D₂ is opened or closed, the second access panel 58 hinges about the hinge line 62 and freely moves with that door. Thus, the access panels 56, 58 allow one to freely access the contents of the refrigerator R by opening either door D₁ or D₂.

As further illustrated in FIG. 5, each access panel 56, 58 includes an opening 64 positioned over a handle H on the doors D1, D2 of the refrigerator R. Thus, the handles H project through the access panels 56, 58 so that they may easily be engaged with the hand to open and close the doors D₁ and D₂ of the refrigerator R.

As should be appreciated, during shipping, the hood 52 is wrapped in a layer of polymer film in the same manner the chest freezer F was wrapped in a layer of polymer film 14 as illustrated in FIG. 2 a. Thus, the alternative embodiment of the cover 50 also forms a protective shell during shipping providing all of the advantages outlined above respecting the first embodiment of the cover 10.

During shipping, the handles H may be covered by the hood 52. After removing the outer layer of polymer film, perforated lines in the hood 52 overlying the handles H may be torn open and the hood 52 may then be pushed around the handles so that the handles H project through the resulting opening or slit where they can be easily engaged.

In FIG. 6, a top mount freezer and bottom mount refrigerator appliance A is illustrated covered in yet another alternative embodiment of the present invention. Specifically, the cover 70 includes a hood 72 having a main body 74, a first access panel 76 and a second access panel 78. The main body 74 covers the two sidewalls and the top wall of the appliance A. The first access panel 76 is connected to the main body 74 by hinge line 77 while the second access panel 78 is connected to the main body 74 by the hinge line 80. As should be appreciated, the first access panel 76 is secured to the first door D₁ of the appliance A while the second access panel 78 is secured to the second door D₂. When the door D₁ is opened or closed, the first access panel 76 hinges about the hinge line 77 and freely opens with the door. Similarly, when the second door D₂ is opened or closed, the second access panel 78 hinges about the hinge line 80 and freely moves with that door. Thus, the access panels 76, 78 allow one to freely access the contents of the freezer and refrigerator by opening the respective doors D₁ and D₂.

Reference is now made to FIG. 7 illustrating yet another embodiment of the present invention for covering a top mount refrigerator door and bottom mount freezer drawer appliance A₂. This cover 84 includes a hood 86 having a main body 88, a first access panel 90 and a second access panel 92. The main body 88 covers the two sidewalls and the top wall of the appliance A₂. The first access panel 90 is connected to the main body 88 by hinge line 94. In addition, the first access panel 90 is secured to the door D₁ of the appliance A₂. Thus, when the door D₁ is opened or closed, the first access panel 90 hinges about the hinge line 94 and freely opens or closes with that door.

In contrast, the second access panel 92 is completely separate from the main body 88. More specifically, the second access panel 92 is sized and shaped to overlie the front face and side margins of the freezer drawer DR. In addition, the access panel 92 includes an opening 96 to allow access to the handle H on the freezer drawer DR. This allows an operator to access the handle to open and close the drawer DR. When this is done the second access panel 92 moves freely with the drawer DR.

FIG. 8 illustrates yet another embodiment of the present invention shown covering a two-door top mount refrigerator and a bottom mount freezer drawer appliance A₃. More specifically, the cover 100 includes a hood 102 having a main body 104, a first access panel 106, a second access panel 108 and a third access panel 110. The first access panel 106 is connected to the main body 104 by the hinge line 112 while the second access panel 108 is connected to the main body 104 by the hinge line 114. As should be appreciated, the first access panel 106 is secured to the first door D₁ of the appliance A₃ while the second access panel 108 is secured to the second door D₂. When the doors D₁, D₂ are opened or closed, the respective first and second access panels 106, 108 hinge about the respective hinge lines 112, 114 and freely move with the doors. Thus, the access panels 106, 108 allow one to freely access the contents of the refrigerator by opening either door D₁ or D₂.

In contrast to the fist and second access panels 106, 108, the third access panel 110 is separate from the main body 104. The third access panel 110 is connected to the freezer drawer DR and covers the front face and side margins of that drawer. As described above with respect to the second access panel 92 in the FIG. 7 embodiment, the third access panel 110 moves freely with the drawer DR as it is opened and closed.

FIG. 9 illustrates yet another alternative embodiment of the present invention on an upright freezer UF. In this embodiment, the cover 120 includes a hood 122 having a main body 124 and a single access panel 126. The main body 124 covers the two sidewalls and the top wall of the upright freezer UF. The access panel 126 is connected to the main body 124 by the hinge line 128. As should be appreciated, the access panel 126 is secured to the door D of the upright freezer UF. Thus, when the door D is opened or closed, the access panel 126 hinges about the hinge line 128 and freely moves with that door. Thus, the access panel 126 allows one to freely access the contents of the upright freezer UF by opening the door D.

The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. Thus, it should be appreciated that the cover 10 of the present invention may include any combination of flaps and access panels to be useful on substantially any design of refrigerator, freezer or refrigerator-freezer regardless of the size, shape and layout of any doors, drawers or the like. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way. 

What is claimed is:
 1. A combined shipping and insulation cover for an electrical appliance, comprising: a hood of insulating material, said hood of insulating material being provided in a shipping position covering said electrical appliance; and a layer of polymer film extending around said hood of insulating material and holding said hood of insulating material on said electrical appliance in said shipping position; said cover being characterized by having a tear off panel connected to said hood by a perforated score line; said hood includes a main body and an access panel, said access panel covering a door of said electrical appliance, said access panel being connected to said door, and said access panel being connected to said main body by a hinge line, whereby said access panel allows said door of the electrical appliance to be opened and closed while the access panel is connected to the door with said cover in place on said electrical appliance after said layer of polymer film is removed.
 2. The cover of claim 1, wherein said hood of insulating material includes a densified outer skin.
 3. The cover of claim 2, wherein said hood of insulating material is a nonlaminate.
 4. The cover of claim 1, wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position.
 5. The cover of claim 4, wherein said protector is held in a pocket on said hood so as to cover and protect said electrical appliance.
 6. The cover of claim 5, wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rabber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof.
 7. The cover of claim 5, wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket.
 8. The cover of claim 1, wherein said hood of insulating material is made from a group consisting of polyester, polyolefm, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof.
 9. The cover of claim 8, wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof.
 10. (canceled)
 11. The cover of claim 1, wherein said access panel includes an opening positioned over a handle on said door of said electrical appliance so that said handle projects through said access panel.
 12. The cover of claim 11, further including a first fastener securing said main body of said hood to said electrical appliance.
 13. The cover of claim 12, further including a second fastener securing said access panel of said hood to said door of said electrical appliance.
 14. A combined shipping and insulation cover for an electrical appliance, comprising: a hood of insulating material, said hood of insulating material provided in a shipping position covering said electrical appliance; and a layer of polymer film extending around said hood of insulating material and holding said hood of insulating material on said electrical appliance in said shipping position; said cover being characterized by said hood including a main body and an access panel, said access panel covering a door of said electrical appliance, said access panel being connected to said door, and said access panel being connected to said main body by a hinge line, whereby said access panel allows said door of said electrical appliance to be opened and closed while the access panel is connected to the door with said cover in place on said electrical appliance after said layer of polymer film is removed.
 15. The cover of claim 14, wherein said hood of insulating material includes a densified outer skin.
 16. The cover of claim 15, wherein said hood of insulating material is a nonlaminate.
 17. The cover of claim 14, wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position.
 18. The cover of claim 17, wherein said protector is held in a pocket on said cover so as to cover and protect said electrical appliance.
 19. The cover of claim 18, wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof.
 20. The cover of claim 18, wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket.
 21. The cover of claim 14, wherein said hood of insulating material is made from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof.
 22. The cover of claim 21, wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof.
 23. The cover of claim 14, wherein said access panel includes an opening positioned over a handle on said door of said electrical appliance so that said handle projects through said access panel.
 24. The cover of claim 23, further including a first fastener securing said main body of said cover to said electrical appliance.
 25. The cover of claim 24, further including a second fastener securing said access panel of said cover to said door of said electrical appliance. 